Personal flotation device comprising liquid impervious buoyant filaments

ABSTRACT

A personal flotation device is described which is in the form of a flexible garment or combination of garments made from liquid impervious filaments of buoyant material. The garment or combination of garments accommodate movement of the wearer while providing the wearer with buoyancy.

FIELD

There is described a personal flotation device that has a differentconstruction and takes a different form from traditional personalflotation devices.

BACKGROUND

Personal flotation devices, or “PFDs”, have evolved over the years fromthe old “Mae West”, or kapok, type of life vests; then, to vinyl coveredfoam rubber life jackets; and, finally, to more specialized flotationdevices which are used when one engages in different types of watersports and boating activities, these more modern PFD's are typicallyfabric covered flotation foam panels sewn into vests, jackets or evenfull body suits. Recently inflation style PFD's have also becomepopular. Typically formed into a vest or belt, they can be activatedmanually or by immersion in water. Compressed air from a high pressurebottle is released into an air holding flotation bladder that isincorporated into a vest or belt.

The U.S. Coast Guard has instituted regulations regarding the minimumflotation required of PFDs. As set forth in those regulations, theminimum flotation required depends upon the expected use of the PFD. TheU.S. Coast Guard Regulations, Title 33 of the Code of

Federal Regulations (“CFR”), Chapter 1, Part 175, Subpart B, requirethat recreational boats have at least one Coast Guard approved PFD onboard for each person on a boat.

In the past, increasing the buoyancy of PFDs has generally required thatthere be an associated increase in the bulk of the PFD, as additionalbuoyant material is required to increase a PFD's buoyancy. The additionof thicker and/or additional buoyant material to a PFD typically resultsin increased bulk which tends to inhibit or restrict the freedom ofmovement of the wearer. This restriction on the freedom of movement ofthe wearer is especially a problem for PFD wearers who are involved instrenuous water sport activities which require a significant amount ofmovement of their arms, shoulders, and torso. By way of example, in kiteboarding, stand up paddle boarding, canoeing, kayaking, rafting,sailing, wind surfing, or similar activities, significant arm, shoulder,and upper torso movement is required when the wearer is paddling ormanoeuvring control bars, sails and lines. In addition, mostconventional PFDs do not tend to move with the wearer. Instead, theytend to ride up, or shift, on the wearer's torso, thereby making the PFDuncomfortable to wear and also interfering with the wearer's mobility.Current PFD solution also restricts the flow of air over the user, whichcan cause discomfort and overheating in hot conditions. Alternatively,the outer fabric coverings on current life jackets hold water which cancause a cooling effect perhaps desirable in the heat, however thisevaporation cooling can add to the chance of hypothermia in coldconditions.

Unfortunately, many persons are preferring to assume a risk of drowningrather that wear an uncomfortable and activity restricting PFD. Inrecent years, concerns regarding non-compliance have caused the U.S.Coast Guard to modify the Regulations regarding minimum flotation forPFDs. Accordingly; PFDs are now segregated into different classes whichdepend upon the type of boating activity in which the PFD is intended tobe used. Generally, there are five classes of PFDs as stipulated withinthe U.S. Coast Guard Regulations. They are designated as Type 1,offshore life jacket; Type 2, near shore buoyant vest; Type 3, flotationaid; Type 4, throwable device; and Type 5, special use device. The Type3 PFDs, or flotation aids, are generally the best suited for mostrecreational water sports in which a significant degree of mobility, andarm and shoulder movement, are involved. Accordingly, they tend to bethe most common type of PFDs in use. The U.S. Coast Guard Regulationsrequire that all Type 3 PFDs have a minimum of 15.5 pounds of flotationwhen they are manufactured. As most adults generally weigh between 10and 12 pounds when submerged in water, i.e., significantly less than theminimum Coast Guard flotation requirement, the provision of at least15.5 pounds of buoyancy is sufficient to help insure that a personwearing such a PFD, properly fitted, will be able to float.

PFDs are generally constructed of a fabric material which encloses or islaminated to a panel of foam material which is used for flotation.Typically, the fabric material is sewn around the foam material therebyenclosing and protecting the flotation foam in a fabric “pocket”. As iswell known in the art, the present design of PFDs includes a number ofsewn pockets, each of which typically retains a cut slab of flotationfoam. The size and shape of the pockets, and the size and shape of theenclosed foam, must, of course correspond to one another. As the foamwhich is typically used in a PFD is firmer than the surrounding fabricmaterial, bending of the PFD can be enhanced by providing a seam betweenadjacent foam-holding pockets. This is commonly referred to as a“quilting seam”. As is well known to those skilled in the art, presentand past PFDs of this type exhibit substantial amounts of sewing, andnumerous seams, in order to provide its desired shape, while enclosing asufficient quantity of flotation foam to provide at least the minimumflotation required by the U.S. Coast Guard regulations for the type ofPFD being manufactured. In addition, the sewn seams allow for increasedbending of the PFD where desired. Even a relatively simple PFD designwill generally include at least two side panels, a back panel, and,typically, at least two front panels (which are usually joined togetherby some sort of closure system, such as straps or a zipper, when the PFDis worn). Thus, even a simple design for a PFD may include five pockets,each of which encloses a piece of flotation foam which has been cut tothe desired shape prior to being inserted into the pocket which isformed in the fabric material to receive the flotation foam. If morecomplicated designs are desired, for example, to provide for moreconformal bending of the PFD, then it is necessary to include additionalseams where such additional bending is desired, as the seams act as the“hinges” between adjacent panels. As quilting seams are added, there isthe obvious loss of space within the empty fabric envelope, whichtranslates into less space available for the flotation material itself,and, therefore, reduced flotation and buoyancy of the PFD. Of course,using current manufacturing techniques and materials, this means thatthere must be additional pieces of foam, and/or pieces of additionalthickness, as well as additional sewn seams, all adding to thecomplexity of the design, the number of seams required, and the labourand material costs associated with manufacturing the PFD. A more recentinnovation is molding the flotation foam in three dimensional shapesthat streamlines the fit of PFD's for action water sports. These formedflotation panels are often laminated with a secondary fabric or filmlayer during the molding/embossing process.

While those skilled in the art will recognize that “belts”, vests,rafts, and some other flotation articles have been made for some time bydipping a flexible flotation foam panels into a liquid vinyl, so thatthe vinyl forms a skin over the foam, the use of such technology hasgenerally been limited to providing flotation devices (belts and vests)for use by water skiers. Typically, devices manufactured using the vinyldipping technology of the prior art are notoriously hot, and they stickto the skin. Further, they typically tend to crack around the edges, sothey were not only uncomfortable, but they cause abrasion, particularlyaround the armholes and sides.

Adding to the foregoing problem is that the U.S. Coast Guard Regulationsrequire that the flotation in a PFD be provided by an approved material,and the only presently approved flotation materials are flotation foams.The U.S. Coast Guard has approved the use of Neoprene as a fabric inmanufacturing PFDs. Neoprene is a soft, elastic, stretchable, flexiblepolychloroprene foam material, which can be laminated to a segmentedpolyurethane known as LYCRA (a synthetic fiber produced by E. I. DuPontde Nemours and Company, located in Wilmington, Del.). While Neoprene,laminated with Lycra, is an approved fabric, neither Neoprene norNeoprene laminated with LYCRA can be used alone to replace flotationfoam. Instead, the laminate is used to enclose an approved foam in aPFD. Other stretch fabrics, such as a spandex omni-directional wrap knitlaminated to a monolithic film which is known as DARLEXX (an elasticfabric produced by Darlington Fabrics Corporation, New York, N.Y.), arenot approved for use to enclose approved flotation foams in PFDs.

SUMMARY

It is an underlying premise that PFDs would be more likely to be worn ifthey had the same fit and comfort as standard clothing and became apreferred garment when in the general marine environment. Such aninnovation would lower the mortality rate due to drowning, as the PFDwould double as a comfortable garment on or off the water. A need hasexisted for a PFD which flexes with, and conforms more naturally to,ami, shoulder, and torso movement of a wearer, so that as the wearermoves, the PFD moves with the wearer. A PFD which moves with the wearer,rather than shifting, is far less likely to become uncomfortable for thewearer or to interfere with, or restrict, the movements of the wearer.

Accordingly, there is provided a personal flotation device which is inthe form of a flexible garment or combination of garments made fromfilaments of liquid impervious buoyant material. The garment orcombination of garments accommodate movement of the wearer whileproviding the wearer with buoyancy.

While there may be various materials that are suitable, beneficialresults may be obtained through the use of a closed cell foam. Closedcell foam is known as a liquid impervious buoyant material. It can alsobe extruded to form filaments of any desired length and any desiredcross-sectional shape.

With the approach described above, there are any number of garments thatcan be made to provide the desired buoyancy. Those garments may include:a jacket, sweater, a vest, a pair of pants, a full body suit, gloves,mitts, socks, belts, arm sleeves, leggings, hats and belts. It must beemphasized that if the new personal flotation device is to be worn asclothing, the desired buoyancy may be achieved through an ensemble ofgarments. For example, government mandated buoyancy standards may be metor exceeded by a combination that includes a sweater, a pair of pantsand a vest.

The properties of the garments will be varied depending upon theenvironment in which they are intended to be worn. For example, whenactive in frigid waters, the garments may be tightly woven or knittedwith a view to provide thermal insulation properties and the combinationmay include gloves, socks, and a hat to reduce loss of body heat. Incontrast, when active in a warm climate, the garments may be looselywoven to allow for cooling ventilation for the comfort of the wearer.

While the thickness of the closed call foam must be sufficient toprovide the necessary buoyancy, it should not be so thick as to restrictmovement. The objective is to have the PFD become an article ofclothing. It is preferred that the thickness vary between 2 mm and 6 mm.Around the torso, the thickness can be 4 mm to 6 mm. However, around thearms and legs, the thickness may be 2 mm to 3 mm, so as to provide thedesired freedom of movement. By controlling the density of the closedcell foam, one is able to increase or decrease the buoyancy with thesethickness dimensions in mind.

Once the basic principle is understood there are various enhancementswhich may be added to enhance the durability, construction andappearance of the garments. Those variations will hereinafter be furtherdescribed.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features will become more apparent from the followingdescription in which reference is made to the appended drawings, thedrawings are for the purpose of illustration only and are not intendedto be in any way limiting, wherein:

FIG. 1 is a perspective view of a prior art PFD;

FIG. 2 is a plan view showing a PFD made from one embodiment of theinvention;

FIG. 3 is a perspective view of a foam flotation filament;

FIG. 4 is a perspective view of a foam flotation filament with anexternal sheath;

FIG. 5 is a sectional view of a segmented flotation filamentencapsulated with an external sheath;

FIG. 6 is a perspective view of a flotation filament with an internalfiber yarn or monofilament line;

FIG. 7 is a perspective view of a flotation filament wrapped with afiber yarn or monofilament line;

FIG. 8 is a perspective view of sealed polymer tubing flotationfilament;

FIG. 9 is a plan view of a woven flotation filament textile;

FIG. 10 is a plan view of a knitted flotation filament textile;

FIG. 11 is a plan view of an embroidered flotation filament textile;

FIG. 12 is a plan view of a chain link flotation filament textile;

FIG. 13 is a perspective view of an interlocking flotation filamenttextile;

FIG. 14 is a perspective view of an intersecting flotation filamenttextile;

FIG. 15 is a plan view of a composite woven flotation filament and yarntextile;

FIG. 16 is a plan view of multiple flotation filaments wound together tomake a flotation yarn;

FIG. 17 is a plan view of multiple flotation filaments braided togetherto make a flotation yarn;

FIG. 18 is a plan view of woven flotation filament textile pieces weldedtogether;

FIG. 19 is a plan view of woven flotation filament textile pieces gluedtogether;

FIG. 20 is a plan view of woven flotation filament textile pieces sewntogether;

FIG. 21 is a perspective view of panels of a PFD made from wovenflotation filament textile;

FIG. 22 is a perspective view of panels of a PFD, made from wovenflotation filament textile, joined together;

FIG. 23 is a sectional view of woven flotation filament textilelaminated on both sides with a woven fabric or film to create amulti-layer composite material;

FIG. 24 is a sectional view of a woven fabric or film laminated on bothsides with a woven flotation filament textile;

FIG. 25 is a plan view of a flotation garment made from woven flotationfilament textile and synthetic fabric;

FIG. 26 is a sectional view of woven flotation filament textile insertedinto textile pocket;

FIG. 27 is a plan view showing sheared woven flotation filament textile;

FIG. 28 is a plan view showing stretched woven flotation filamenttextile;

FIG. 29 is a sectional view showing a flotation filament textile with ahard shell;

FIG. 30 is a plan view of a flotation garment made from a knittedflotation filament textile.

DETAILED DESCRIPTION

A personal flotation device, and the manner of making the same, will nowbe described with reference to FIG. 1 through FIG. 30.

Structure and Relationship of Parts:

The process of extruding, molding, slicing, shaping closed cell foamssuch as PE, EPE, EVA, Neoprene, Silicone and NBR has allowed for thecreation of very light floating (buoyant) filaments to be manufacturedin a wide variety of diameters, densities, profiles and shapes .Depending on the density of the foam, the flotation filament in its purefrom can be woven into a fabric, which is then cut into pattern piecesfor assembly into a form fitting garment. The cut edges of the patternpieces can be attached to one another by sewing, welding, gluing orother connection methods to seal the foam filaments and connect thepattern pieces. By using a knitting, process the flotation filaments canalso be woven directly into formed shapes using a process similar toknitting sweaters. Tubular shapes, garments and shaped covers can bemanufactured.

With lower density flotation filaments it may be desirable to cover orsheath the flotation filaments with fabrics coverings such as Lycra. Bycovering a flotation filament with a Lycra sleeve, it is possible tomeet the US Coast Guard Type 3 material certification allowing thecreation of certified flotation garment providing the minimum flotationof 15.5 pounds is achieved. Adding the Lycra covering to the flotationfilament would also increase the durability and abrasion resistancewhile improving the stretch characteristics of the flotation filament.Flotation filaments can also be sheathed or covered with moderntechnical fabrics such as Kevlar for or Nomex for their specificproperties in strength and fire resistance, however this may negate USCoast Guard Approval. Flotation filaments can also be supported bysingle yarns of woven fibres such as carbon or spectra if stretch is notdesired in the flotation filament.

Flotation filaments can be woven in various configurations and tensionsto create varying gaps or spaces between the flotation filaments weave.Tighter weaves offer less breathability while increasing protection fromelements such as wind, rain, and immersion in water. Looser or more openweaves of the flotation filaments will allow more air transfer betweenthe filaments providing additional breathability, ideal for warmerconditions. A more open weave of the flotation filaments would also bedesirable if flotation weave panels are sandwiched between or attachedto woven fabric or film layer. An example of this would be replacingsolid foam panel as used in traditional life jackets with a flotationweave panel.

The correct combination of density and durability in the flotationfilaments will allow a one piece garment, jacket, pants, hat or otherbodily worn accessories to be woven with the flotation filaments. Agarment woven with flotation filaments can be worn as insulated clothingas the filaments provide comfort, stretch, insulation and breathabilityto the user, similar to wearing a garment made with natural or syntheticfibres spun or twisted into a yarn. In the marine environment a garmentwoven partially or in its entirety with flotation filaments willtransform the garment into a comfortable personal flotation device orPFD. An example of this would be a jacket with the torso that is wovenwith flotation filaments while the arms are constructed with a fabricconsisting of yarns spun with synthetic fibres. Panels or inserts ofwoven flotation filaments could also be used to enhance the performanceof traditional style PFD's or flotation garments by replacing thenon-breathing, low stretch solid sheet flotation foam. The wovenflotation filaments can be suspended within a sandwich of overlayingfabrics that provide abrasion, weather protection and enhanced stabilityto the flotation filament weave.

Flotation filaments woven into a panel or sheet can also be laminated tobacking fabrics by use of adhesives to polymer membranes such as Teflon,PU, PPE. Laminated to such membranes, the textile would be locked intoplace and made waterproof and breathable. Flotation filaments woven intoa textile can also be laminated by use of adhesive films or heat toother woven fibre textiles such as Nylon, Kevlar, and Lycra providingadditional stability, abrasion and weather resistance to flotationfilament textile.

The flotation filament textile can also be laminated into a compositematerial similar to neoprene sheet goods for use in the manufacture ofitems like wetsuits and dry-suits. With the flotation filament textileproviding flotation, insulation and stretch, additionally laminatedfabrics or films would provide additional heat retention, abrasionresistance, support and UV protection to flotation filament textile fromthe marine environment.

The flotation filaments can be formed into textiles sheets or rolls bytraditional weaving techniques as used with fibre spun yarns when theyare woven into textiles. The flotation filaments can also be connectedby interlocking profile shapes that allow the flotation filaments to beinterlocked by the nesting, profile of the flotation filament.

The flotation filaments can be further connected by intersectingfilaments or yarns via pass through slots or holes molded or cut intothe flotation filaments. Individual flotation filaments can be twistedtogether to create flotation yarns, which in turn can be woven into aflotation fabric. The flotation filaments can also be formed intoflotation filament links. These links which can be closed or open inshape are then connected by interlocking, or by other means such asglue, welding, clips, yarns or monofilaments to create a textile. Theresulting fabric of this style of assembly would be similar to chainmail. The links can be circular, square, or of any shape and profile.The links can be a closed or open shape as long as they interconnecttogether and creates a textile that be used for a PFD's, garment orother non-apparel applications. Weaves of flotation filament can be alsobe embossed via pressure, heat and adhesives to fuse the filaments ormodify the profile and density of the flotation filament textile.

The buoyant flotation filaments described above enable the manufactureof PFDs using U.S. Coast Guard approved flotation materials that doesnot upon rely the standard methods of construction using foam panels,laminated, quilted or in pure non-laminated state, cut into flat patternpieces using that use shaping seams and stretch panels or gussets toform vests, jackets, pants or full body suits. The buoyant flotationfilaments form a garment to allow high comfort and breathability to useras found with non-flotation garments such as knitted sweaters or wovengarments used outside the PFD market. Use of the buoyant filamentsresults in a garment for the marine environment, that is as comfortableto wear as standard clothing, to be used for both insulation andflotation as it could worn at all times, and used under productiveshielding garments such a rain pants, jackets, wetsuits or dry-suits. Itis feasible that a mixture of closed cell flotation filaments and otherfilaments could be used on the same garment or covering to offerflotation, insulation and cooling.

It will be appreciated by a person skilled in the art that the garmentthat serves as a PFD, could be made for an animal, such as the familydog. In such case, the “wearer” would be the dog. It will also beappreciated that the flotation filaments can be treated withanti-microbial, anti-fungal and other agents. It will further beappreciated that, as long as the necessary buoyancy is maintained, theflotation filaments may be combined with other filaments. It will beappreciated that the flotation filaments have other properties that makethem desirable in marine applications. For example, the flotationfilaments provide padding. If padding is desirable in a particularapplication, the size of the flotation filaments can be increased tointentionally enhance the padding feature.

LEGEND OF REFERENCE NUMERALS

1—Flotation filament

2—Flotation filament Link

3—Interlocking Flotation filament

4—Slot in Flotation filament

5—Fiber Yarn or Monofilament Strand

6—Panel made from Woven Flotation Filaments

7—Personal Flotation Device Made From Woven Flotation filament Textile

8—Welded Connection

9—Glued Connection

10—Fabric Strip

11—Sheath

12—Fiber Yarn or Monofilament Strand

13—Polymer Tubing

14—Plug

15—Mesh Fabric

16—Woven fabric or Film

17—Sewing

18—Gap or Space Between Flotation filament Weave

19—Interlocking Connection

20—Zipper

21—Flotation Garment Made From Woven Flotation filament Textile andSynthetic Fabric

22—Sleeves Made From Synthetic Fabric

23—Woven Flotation filament Textile

24—Textile Pocket

25—Pulling Force

26—Protective Hard Shell

27—Knitted Flotation filament Textile

28—Flotation Garment Made From Knitted Flotation filament Textile

In this patent document, the word “comprising” is used in itsnon-limiting sense to mean that items following the word are included,but items not specifically mentioned are not excluded. A reference to anelement by the indefinite article “a” does not exclude the possibilitythat more than one of the element is present, unless the context clearlyrequires that there be one and only one of the elements.

The scope of the claims should not be limited by the illustratedembodiments set forth as examples, but should be given the broadestinterpretation consistent with a purposive construction of the claims inview of the description as a whole.

1-20. (canceled)
 21. A personal flotation device comprising: an item ofclothing that is worn in place of standard everyday casual clothing, theitem of clothing being made from flotation filaments of liquidimpervious closed cell polymer foam having buoyancy when immersed inwater, a cross-sectional thickness of between 2 mm to 6 mm and stretchproperties that enable the item of clothing to conform to a body of awearer and flex during movement, the item of clothing providing buoyancyand being chosen from a jacket with sleeves, sweater with sleeves, apair of pants, gloves, mitts, socks, arm sleeves, leggings, and hats.22. The personal flotation device of clam 21, wherein the item ofclothing has insufficient buoyancy to meet personal flotation deviceflotation standards of a minimum 15.5 pounds of buoyancy to the wearer,two or more items of clothing being combined so that the ensemble meetsthe personal flotation device flotation standards.
 23. The personalflotation device of claim 21, wherein the filaments are sheathed orcovered with one or more materials to improve durability.
 24. Thepersonal flotation device of claim 21, wherein the filaments aresegmented into segmented pieces and then sheathed or covered with one ormore materials to encapsulate the segmented pieces.
 25. The personalflotation device of claim 21, wherein the filaments take the form ofconnecting links and the item of clothing takes the form a chain mailgarment.
 26. The personal flotation device of claim 25, wherein theconnecting links are connected to form the item of clothing by one ofinterlocking, weaving, gluing, welding, or clipping.
 27. The personalflotation device of claim 21, wherein each of the filaments has asupporting fiber yarn or monofilament line forming a composite filament.28. The personal flotation device of claim 27, wherein the compositefilament has the filaments wrapped by one or more supporting fiber yarnsor monofilament lines.
 29. The personal flotation device of claim 21,wherein an interlocking profile is provided whereby the filaments arealigned and connected.
 30. The personal flotation device of claim 21,wherein the filaments are woven together by inserting one of the standsthrough a slot or slots in other of the filaments.
 31. The personalflotation device of claim 21, where the filaments that are laminated onone or both sides with woven fabrics or films to create multi-layercomposite material.
 32. The personal flotation device of claim 28,wherein the composite filament have an outer layer of formed by thestrand and a central layer of fabric or film.
 33. The personal flotationdevice of claim 28, wherein the composite filament have an inner layerformed by the strand and an outer layer of fabric or film.
 34. Thepersonal flotation device of claim 28, wherein the filaments are formedinto shapes or panels and inserted into supporting textile pockets orenvelopes to add insulation, cooling or flotation to item of clothing.35. The personal flotation device of claim 21, wherein the item ofclothing has a torso portion and a sleeve portion, the torso portion hasa thickness of 4 mm to 6 mm as a torso covering and the sleeve portionhas a thickness of 2 mm to 3 mm.
 36. The personal flotation device ofclaim 21, wherein the item of clothing is tightly woven to providethermal insulation properties to reduce loss of body heat.
 37. Thepersonal flotation device of claim 21, wherein the item of clothing isloosely woven to allow for cooling ventilation.
 38. The personalflotation device of claim 21, wherein the item of clothing is knitted toa desired shape without any seams.
 39. A method of forming a personalflotation device, the method comprising: providing an item of clothingthat is worn in place of standard everyday casual clothing, the item ofclothing being made from flotation filaments of liquid impervious closedcell polymer foam having buoyancy when immersed in water, across-sectional thickness of between 2 mm to 6 mm and stretch propertiesthat enable the item of clothing to conform to a body of a wearer andflex during movement, the item of clothing providing buoyancy and beingchosen from a jacket with sleeves, sweater with sleeves, a pair ofpants, gloves, mitts, socks, arm sleeves, leggings, and hats; formingthe item of clothing so as to have insufficient buoyancy to meetpersonal flotation device flotation standards; and combining at leasttwo of the items of clothing so that the ensemble meets personalflotation device flotation standards.